Climate control systems and methods

ABSTRACT

A method for thermally conditioning a space adjacent a seat assembly includes activating a heating element positioned within the seat assembly beneath a seat covering. A fluid module that includes a fluid supply device and a thermoelectric element is activated to direct heated air from the fluid module to a space adjacent the seat assembly through a distribution system formed at least partially in the seat cushion. After a period of time, the heating element is deactivated.

PRIORITY INFORMATION

This application is a continuation of co-pending U.S. patent applicationSer. No. 11/525,528, filed Sep. 22, 2006, which is acontinuation-in-part of U.S. patent application Ser. No. 11/087,215,filed Mar. 23, 2005 and now abandoned, the entireties of both of whichare hereby expressly incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to temperature control. More specifically, thisinvention relates to temperature control of a seat.

2. Description of the Related Art

Temperature modified air for environmental control of living or workingspace is typically provided to relatively extensive areas, such asentire buildings, selected offices, or suites of rooms within abuilding. In the case of vehicles, such as automobiles, the entirevehicle is typically cooled or heated as a unit. There are manysituations, however, in which more selective or restrictive airtemperature modification is desirable. For example, it is oftendesirable to provide an individualized climate control for an occupantseat so that substantially instantaneous heating or cooling can beachieved. For example, an automotive vehicle exposed to the summerweather, where the vehicle has been parked in an unshaded area for along period, can cause the vehicle seat to be very hot and uncomfortablefor the occupant for some time after entering and using the vehicle,even with normal air conditioning. Furthermore, even with normalair-conditioning, on a hot day, the occupant's back and other pressurepoints may remain sweaty while seated. In the winter, it is highlydesirable to have the ability to warm the seat of the occupant quicklyto facilitate the occupant's comfort, especially where the normalvehicle heater is unlikely to warm the vehicle's interior as quickly.

For such reasons, there have been various types of individualizedtemperature control systems for vehicle seats. Such temperature controlsystems typically include a distribution system comprising a combinationof channels and passages formed in the back and/or seat cushions of theseat. A thermal module thermally conditions the air and delivers theconditioned air to the channels and passages. The conditioned air flowsthrough the channels and passages to cool or heat the space adjacent thesurface of the vehicle seat.

There are, however, drawbacks with existing temperature control systemsfor seats. For example, in particularly adverse conditions, it may takethe conditioned air a long period of time to heat noticeably the seat.In addition, while climate control systems that use thermal modulesprovide many advantages, they are relatively expensive and thus may notbe suitable for all applications.

Thus, there is a need for an improved temperature control apparatus fora climate control system for seats.

SUMMARY OF THE INVENTION

Accordingly, one aspect of the present invention comprises a method forthermally conditioning a space adjacent a seat assembly that includesactivating a heating element positioned within the seat assembly beneatha seat covering. A fluid module that includes a fluid supply device anda thermoelectric element is activated to direct heated air from thefluid module to a space adjacent the seat assembly through adistribution system formed at least partially in the seat cushion. Aftera period of time, the heating element is deactivated.

Another aspect of the present invention comprises a climate controlledseat assembly that includes a seat cushion having an outer surface. Asupply passage extends through the seat cushion and includes an inlet. Adistribution system comprises at least one distribution passageconfigured to distribute air along the support surface of the seatcushion. The distribution system communicates with the supply passage. Aseat covering is positioned over the outer surface of the seat cushion.A heat source is positioned between the seat covering and the inlet tothe supply passage. A fluid module is operatively connected to the inletof the supply passage. The fluid module includes a fluid transfer deviceconfigured to move air between the distribution system and the supplypassage and a thermoelectric device configured to heat air moving thefluid module. A control system is configured to activate, upon receivingan input signal generated by a user, the fluid module to provide heatedair to the outer surface of the seat cushion and to activate the heatsource for a predetermined period of time.

Another aspect of the present invention comprises a seat cushion havinga front or top side configured to support an occupant and a generallyopposing rear or bottom side. Fluids passages extend through from rearor bottom side of the seat cushion to the front or top side of the seatcushion. A fluid module includes a fluid device configured to move fluidwithin the fluid passages and a thermal element configured only to coolfluid moved by the fluid device. A restive heater is disposed on thefront or top side of the seat cushion.

Another aspect of the present invention comprises a method for thermallyconditioning a space adjacent a seat assembly that includes a seatcushion that defines a support surface and seat covering that covers thesupport surface of the seat cushion. The method comprises, during aheating mode, activating a heating element positioned within the seatassembly to heat the space adjacent the seat assembly. During a coolingmode, cooled air is directed from a fluid module that includes athermoelectric unit and a fluid transfer device to the space adjacentthe seat assembly through a distribution system formed at leastpartially in the seat cushion to cool the space adjacent the seatassembly.

Another aspect of the present invention relates to a method forthermally conditioning a space adjacent a seat assembly that includes aseat cushion that defines a support surface and seat covering thatcovers the support surface of the seat cushion. The method comprises,during a first mode, directing heated air from a fluid module thatincludes a thermoelectric unit and a fluid transfer device to the spaceadjacent the seat assembly through a distribution system formed at leastpartially in the seat cushion to heat the space adjacent the seatassembly. During a second mode, a heating element positioned within theseat assembly between the seat covering and the fluid module isactivated while directing heated air from the fluid module through thedistribution system to heat the space adjacent the seat assembly.

Further features and advantages of the present invention will becomeapparent to those of ordinary skill in the art in view of the detaileddescription of preferred embodiments which follow, when consideredtogether with the attached drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle seat assembly, which includesa climate control system that is configured in accordance with apreferred embodiment of the present invention;

FIG. 2 is a side view of the vehicle seat assembly of FIG. 1;

FIG. 2A is a cross-sectional view of the vehicle seat assembly of FIG. 1taken along line 2A-2A of FIG. 2;

FIG. 2B is a cross-sectional view of the vehicle seat assembly of FIG. 1taken along line 2B-2B of FIG. 2;

FIG. 3 is a front view of the vehicle seat assembly of FIG. 1 with acovering of the seat vehicle assembly removed;

FIG. 3A is an exploded, side perspective view of a backrest of thevehicle seat assembly of FIG. 1;

FIG. 4 is a schematic illustration of the vehicle seat assembly andclimate control system of FIG. 1;

FIG. 5A is a cross-sectional view of a backrest of a modified embodimentof a vehicle seat assembly;

FIG. 5B is a cross-sectional view of a seat of a modified embodiment ofa vehicle seat assembly;

FIG. 6A is a cross-sectional view of a backrest of another modifiedembodiment of a vehicle seat assembly; and

FIG. 6B is a cross-sectional view of a seat of an additional modifiedembodiment of a vehicle seat assembly.

FIG. 7 is a graphical illustration of the power supplied to a heatingelement and a fluid module of an embodiment of a climate control system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1 and 2 illustrate an exemplary embodiment of a seat assembly 30that comprises a seat portion 32 and a backrest portion 34. The seatassembly 30 includes a climate control system 36, which will bedescribed in more detail below with reference to FIGS. 2A-4.

When an occupant sits in the seat assembly 30, the occupant's seat islocated generally in a seat area 40 of the seat portion 32 and at leasta portion of their legs are supported by a thigh area 42 of the seatportion 32. In this embodiment, a rear end 44 of the seat portion 32 iscoupled to a bottom end 46 of the backrest portion 34. When the occupantsits in the seat assembly 30, the occupant's back contacts a frontsurface 48 of the backrest portion 34 and the occupant's seat and legscontact a top surface 50 of the seat portion 32. The surfaces 48, 50cooperate to support the occupant in a sitting position. The seatassembly 30 can be configured and sized to accommodate occupants ofvarious size and weight.

In the illustrated embodiment, the seat assembly 30 is similar to astandard automotive seat. However, it should be appreciated that certainfeatures and aspects of the seat assembly 30 described herein may alsobe used in a variety of other applications and environments. Forexample, certain features and aspects of the seat assembly 30 may beadapted for use in other vehicles, such as, for example, an airplane, aboat, or the like. Further, certain features and aspects of the seatassembly 30 may also be adapted for use in stationary environments, suchas, for example, a chair, a sofa, a theater seat, a mattress, and anoffice seat that is used in a place of business and/or residence. Otherconfigurations of the seat assembly 30 are also anticipated, such as,for example, bench seating.

With continued reference to FIGS. 1 and 2, the backrest portion 34 has afront side 54, a rear side 56, a top side 58 and a bottom side 60. Thebackrest portion 34 includes a pair of sides 57, 59 extending betweenthe top side 58 and bottom side 60 for providing lateral support to theoccupant of the seat assembly 30. A lumbar region 62 of the backrestportion 34 is generally positioned between the sides 57, 59 of thebackrest portion 34 near the seat portion 32.

In a similar manner, the seat portion 32 has a front side 64, a rearside 66, a top side 68 and a bottom side 70. The seat portion 32 alsoincludes a pair of sides 69, 71, which extending from the rear side 66and the front side 64 for providing lateral support to the occupant ofthe seat assembly 30. In one embodiment, the seat assembly 30 is securedto a vehicle by attaching the bottom side 70 of the seat portion 32 tothe floor of a vehicle.

FIG. 2A is a cross-sectional view of a portion of the backrest portion34. As shown, the backrest portion 34 is generally formed by a cushion72, which is covered with an appropriate covering material 74 (e.g.,upholstery, leather or vinyl). The cushion 72 is usually supported on ametallic or plastic frame (not shown). In some embodiments, springs maybe positioned between the frame and the cushion 72. The frame providesthe seat assembly 30 with structural support while the cushion 72provides a soft seating surface. The covering material 74 provides anaesthetic appearance and soft feel to the surface of the seat assembly30. The seat portion 32 of FIG. 2B may be constructed in a similarmanner as the backrest portion 34 as shown in FIG. 2A.

FIG. 3 illustrates the seat assembly 32 with the covering 74 removedthereby exposing the cushion 72. The cushion 72 can be a typicalautomotive seat cushion foam or other types of materials with suitablecharacteristics for providing support to an occupant. Such materialsinclude, but are not limited to, closed or open-celled foam.

As shown in FIGS. 3 and 3A, the backrest portion 34 of the seat assembly30 is provided with a backrest fluid distribution system 76A. Thedistribution system 76A comprises an inlet passage 78A that extendsthrough from the front side 54 to the rear side 56 of the seat cushion72. (See also FIG. 2A). The distribution system 76A also includes atleast one, and often, a plurality of channels 80A, which extend from theinlet passage 78A. As mentioned above, the cushion 72 may be formed froma typical automotive cushion material, such as, for example, an open orclosed-cell foam. In one embodiment, the cushion 72 is made of foam thatis pre-molded to form the passage 78A and/or the channels 80A. Inanother embodiment, the passage 78A and/or the channels 80A may beformed by cutting foam out of the seat cushion 72.

With particular reference to FIG. 3A, in the illustrated embodiment, aninsert or liner 150 may be positioned within the channels 80A, 80B fordistributing the air. As shown, the insert 150 generally comprises abody 152, which includes a plurality of channels or plenums 154 with agenerally U-shaped cross-section. The insert 150 is configured to fitgenerally with the channels 80A formed in the cushion 72. The plenums154 extend from a duct 156 that extends through the inlet passage 78A.The periphery of the plenums 154 and duct 156 includes a flange 158 thatextends generally parallel to the surface of the cushion 71. See FIG.2A. The insert 150 is preferably formed of a moisture resistant, closedcell foam, which is configured to limit seepage of air into the cushion72. However, in other embodiments, the insert 150 can be formed fromother materials, such as, for example, molded plastic. Further detailsand additional embodiments of the insert 150 are provided in co-pendingU.S. patent application Ser. No. 10/853,779, filed May 25, 2004, theentire contents of which are hereby incorporated by reference herein. Aswill be described below with reference to FIG. 2B, in a modifiedembodiment, the distribution system 76A may be formed without the insert150.

With reference back to FIG. 2A, a cover or scrim 81A is positionedgenerally over the insert 150 to define distribution passages 82A fortransporting air through the seat assembly 30. The scrim 81A includesone or more openings 84A for transporting air to and/or from thedistribution passages 82A and preferably provides structural support toprevent or reduce the seat cover 74 from depressing into the passages82A. The scrim 81A preferably includes one or more thermal elements160A, which are preferably positioned within the scrim 81A generallyadjacent the one or more openings 84A and are configured to effect atemperature change in the space adjacent the seat assembly 30. As willbe explained in more detail below, in the illustrated embodiment, thethermal elements 160A are used to heat the air transported through theseat assembly and/or heat the portions of the seat assembly adjacent thethermal elements 160A.

The thermal elements 160A may comprise any of variety of devices forcausing a temperature change, such as, for example, resistive heaters(e.g., resistive wires, carbon fiber based heating elements, and carbonimpregnated sheets), chemical-reaction heaters, heat exchanges and/orPeltier thermoelectric devices. The thermal elements 160A may be used incombination with fabrics, foams etc. to form the scrim 81A. In anotherembodiment, the thermal elements 160A may be coupled to or positionedgenerally near the scrim 81A. In the illustrated embodiment, the scrim81A is attached to the flange 158 in a manner that limits leakagebetween the scrim 81A and insert 150 thereby directing the flow of airthrough the openings 84A. In one embodiment, an adhesive is used toattach the scrim 81A to the insert 150. In other embodiments, a heatstake or fasteners may be used.

With continued reference to FIG. 2A, an optional distribution layer 86Ais disposed between the scrim 81A and the seat covering 74. Thedistribution layer 86A spreads the air flowing through the openings 84Aalong the lower surface of the covering 74. To permit airflow betweenthe distribution layer 86A and the spaces proximal to the front surface48 of the backrest portion 34, the covering 74 may be formed from anair-permeable material. For example, in one embodiment, the covering 74comprises an air-permeable fabric made of natural and/or syntheticfibers. In another embodiment, the covering 74 is formed from a leather,or leather-like material that is provided with small openings orapertures. In a modified embodiment, the distribution layer 86A may beomitted or combined with the seat covering 74 and/or the scrim 81A. Asmentioned above, the scrim 81A is configured to allow for the passage ofair. In the illustrated embodiment, this is accomplished by providingthe scrim 81A with small openings or apertures. In another embodiment,the scrim 81A itself and/or the thermal elements 160A may be generallyair-permeable

With reference to FIGS. 2B and 3, the seat portion 32 of the seatassembly 30 is also provided with a seat distribution system 76B. Theseat distribution system 76B comprises an inlet passage 78B that extendsfrom the top side 68 to the bottom side 70 of the seat cushion 72. Aswith the backrest distribution system 76A, the seat distribution system76B also includes at least one, and often, a plurality of channels 80B,which extend from the inlet passage 78B. These channels 80B may beconfigured as described above.

In the seat distribution system 76B, the portion of the cushion 72 thatforms the channels 80B is preferably treated and/or covered with acoating, skin or other material configured such that air flowing throughthe channels 80B does not significantly seep into the cushion 72. Inanother embodiment, the cushion 72 may be formed from a dense foam thatdoes not allow for significant seepage of air through the foam. Inaddition to or in the alternative, the seat distribution system 76B mayinclude an insert or liner as described above with reference to FIGS. 2Aand 3A.

The channels 80B are covered by a scrim or cover 81B to definedistribution passages 82B for transporting air through the seat assembly30. The scrim 81B is preferably configured as described above.Accordingly, the scrim 81B includes thermal elements 160B and one ormore openings 84B for delivering air to and/or from the distributionpassages 82B. As described above, the scrim 81B is preferably attachedto the cushion 72 in a manner that limits leakage between the scrim 81Band cushion 72. A distribution layer 86B is optionally disposed betweenthe scrim 81B and the seat covering 74. As mentioned above, in amodified embodiment, the distribution layer 86B can be omitted orcombined with the seat covering 74 and/or the scrim 81A. In addition, aswith the covering 74, the scrim 81A itself may be configured such thatit is generally air-permeable and/or provided with small openings orapertures 84B as shown in the illustrated embodiment.

As will be explained in more detail below, the thermal elements 160A,160B are used to change the temperature (e.g., increase) in the space orportions of the seat adjacent the occupant of the seat assembly 30. Thethermal elements 160A, 160B are preferably used in combination withfluid flow provided through the distribution system 76A, 76B. Asexplained below, when used in combination with fluid flow, the air maybe conditioned or unconditioned before the thermal elements 160A, 160Bchanges its temperature. For example, in one embodiment, air (which canbe heated) is delivered to the distribution passages 82A, 82B throughthe inlet passages 78A, 78B. The air then flows through the openings84A, 84B and into the distribution layers 86A, 86B. The air is thendirected through the covering 74 to a space adjacent to the frontsurface 48 of the backrest portion 34 and/or the top surface 50 of theseat portion 32. In another embodiment, the climate control system 36 isused to remove air, which is adjacent to the front surface 48 of thebackrest portion 34 and/or the top surface 50 of the seat portion 32. Insuch an embodiment, the air is withdrawn through the covering 74 andinto the distribution layers 86A, 86B. The air is then withdrawn throughthe openings 84A, 84B, into the distribution passages 82A, 82B andthrough the inlet passages 78A, 78B. In this manner, the air withdrawnand/or supplied through the distribution systems 76A, 76B may be used tosupplement and/or enhance the thermal elements 160A, 160B. In oneembodiment, thermal elements 160A, 160B provide heat to the occupant viaconduction through the covering 74 and other layers of material. In suchan embodiment, the fluid flow can enhance the thermal elements 160A,160B by also transferring the heat generated by the thermal elements160A, 160B to the occupant via convection.

Given the goal of distributing air through the cushion 72 and along thecovering 74, those of skill in the art will recognize that thedistribution systems 76A, 76B for the backrest portion 34 and the seatportion 32 may be modified in several different manners. For example,the shape and/or number of channels 80A, 80B and/or openings 84A, 84Bmay be modified. In other embodiments, the scrim 81A, 81B and/ordistribution passages 82A, 82B may be combined and/or replaced withother components configured for similar functions. In other embodiments,the distribution systems 76A, 76B or portions thereof may be combinedwith each other. In addition, various features of the distributionsystems 76A, 76B of the backrest portion 34 and seat portion 32 may becombined and/or interchanged with each other.

FIG. 4 is a schematic illustration of the temperature control system 36.In the illustrated embodiment, the temperature control system 36includes the thermal elements 160A, 160B and the distribution systems76A, 76B described above. The system 36 also includes a back fluidmodule 92A and seat fluid module 92B. As will be explained below, bothfluid modules 92A, 92B are configured to provide and/or remove fluidfrom the distribution systems 76A, 76B described above and/or provideconditioned air (e.g., heated air) to the distribution systems 76A, 76B.In this manner, the fluid modules 92A, 92B provide a fluid flow to/fromthe seat assembly 30, which can be used to enhance or supplement theheat provided by the thermal elements 160A, 160B described above.

In the illustrated embodiment, the fluid modules 92A, 92B preferablyeach include a thermoelectric device 94A, 94B for conditioning (e.g.,selectively healing or cooling) the fluid flowing through the device94A, 94B. A preferred thermoelectric device 94A, 94B is a Peltierthermoelectric module, which is well known in the art. The illustratedfluid modules 92A, 92B preferably also include a main heat exchanger96A, 96B for transferring or removing thermal energy from the fluidflowing through the modules 92A, 92B and to the distribution systems76A, 76B. Such fluid is transferred to the distribution systems 76A, 76Bthrough conduits 98A, 98B (see e.g., U.S. application Ser. No.10/973,947, filed Oct. 25, 2004, which is hereby incorporated byreference herein). In the illustrated embodiments, the modules 92A, 92Balso preferably include a waste heat exchanger 100A, 100B (see FIG. 4)that extends from the thermoelectric device 94A, 94B generally oppositethe main heat exchanger 96A, 96B. A pumping device 102A, 102B ispreferably associated with each fluid module 92A, 92B for directingfluid over the main and/or waste heat exchangers 96A, 96B, 100A, 100B.The pumping devices 102A, 102B may comprise an electrical fan or blower,such as, for example, an axial blower and/or radial fan. In theillustrated embodiment, a single pumping device 102A, 102B may be usedfor both the main and waste heat exchanges 96A, 96B, 100A, 100B.However, it is anticipated that separate pumping devices may beassociated with the waste and heat exchanges 96A, 96B, 100A, 100B.

It should be appreciated that the fluid modules 92A, 92B described aboverepresents only one exemplary embodiment of a device that may be used tomove and/or condition the air supplied to the distribution systems 76A,76B. Any of a variety of differently configured fluid modules may beused to move and/or provide conditioned air. Other examples of fluidmodules that may be used are described in U.S. Pat. Nos. 6,223,539,6,119,463, 5,524,439 or 5,626,021, which are hereby incorporated byreference in their entirety. Another example of such a fluid module iscurrently sold under the trademark Micro-Thermal Module™ by Amerigon,Inc. In another example, the fluid module may comprise a pump devicewithout a thermoelectric device and/or waste heat exchanger forthermally conditioning the air. In such an embodiment, the pumpingdevice may be used to remove or supply air to the distribution system76A, 76B. In yet another embodiment, the fluid modules 92A, 92B, mayshare one or more components (e.g., pumping devices, thermoelectricdevices, etc.) with each other and/or with the vehicles general climatecontrol system. In another embodiment, a single fluid module is used tosupply air to both distribution systems 76A, 76B.

In operation, fluid in the form of air can be delivered from the fluidmodules 92A, 92B, through the conduits 98A, 98B to the correspondingdistribution systems 76A, 76B. As described above, the air flows throughthe passages 82A, 82B, into the openings 84A, 84B and then along thedistribution layers 86A, 86B and through the coverings 74. In thismanner, conditioned or unconditioned air can be provided to the frontsurface 48 of the backrest portion 34 and/or the top surface 50 of theseat assembly. As mentioned above, the air supplied to the seat assemblymay enhance or supplement the thermal elements 160A, 160B.

In a modified embodiment, air from within the passenger compartment ofthe automobile can be drawn through the covering 74, into thedistribution layers 86A, 86B and through the openings 84A, 84B. The airthen can flow through the distribution passages 82A, 82B, into the inletpassages 78A, 78B and then into the conduit 98A, 98B. In this manner,the temperature control system 36 can provide suction so that air nearthe surface of the seat assembly 30 is removed. As mentioned above, theair removed from the seat assembly 30 may enhance or supplement thethermal elements 160A, 160B.

An exemplary control system 104 for the temperature control system 36will now be described with continued reference to FIG. 4. As shown, thecontrol system 104 includes a user input device 106 through which theuser of the climate control system 36 can provide a control setting orset mode for the climate control system 36. The control setting cancomprise a specific temperature setting (e.g., 65 degrees), a moregeneral temperature setting (e.g., “hot” or “cold”), and/or a settingfor the pumping device (e.g., “high,” “medium,” or “low”). Dependingupon the desired configuration, the input device 106 may include any ofa variety of input devices, such as, for example, dials, buttons,levers, switches, etc. The user input device 106 may also include a useroutput that provides visual or audio indicia of the control setting(e.g., an LED display).

With continued reference to FIG. 4, the input device 106 is operativelyconnected to a control module 110. The control module 110 is, in turn,operatively connected to the pumping devices 102A, 102B and thethermoelectric devices 94A, 94B of the fluid modules 92A, 92B for thebackrest portion 34 and seat portion 32. The control unit 110 is alsooperatively connected through control lines (not shown) to the thermalelements 160A, 160B. Temperature sensors 112, 124 are provided tomeasure the temperature of the fluid conditioned by the thermoelectricdevices 94A, 94. The temperature sensors 112, 124 are also operativelyconnected to the seat control module 110. Temperature sensors (notshown), which are preferably located near or proximate to the thermalelements 160A, 160B may also be operatively connected to the controlmodule 110.

In the illustrated embodiment, the control module 110 is operativelyconnected to a power source 114 and a ground source 116 and includes anappropriate power control unit to provide sufficient electrical capacityto operate one, a plurality or all of the aforementioned devices (92B,92B, 112, 124, 160A, 160B). In some embodiments, the seat control module110 also has a controller that is configured to receive the occupantinputs from the input device 106 and the temperature information fromthe temperature sensors 112, 124. From this information, the seatcontrol module 110 is configured to adjust the operation of the thermalelements 160A, 160B, the thermoelectric devices 94A, 94B and/or thefluid pumps 102A, 102B according to a predetermined logic designed toensure occupant comfort and to protect against system damage.

Those of skill in the art will appreciate that the seat control module110 can comprise a hard-wired feed back control circuit, a dedicatedprocessor or any other control device that can be constructed forperforming the steps and functions described herein. In addition, thecontroller within the control module 110 may be combined or divided intosubcomponents as deemed appropriate. For example, it may be advantageousto divide the control module into a first module for conditioning thebackrest portion 34 and a second control module for conditioning theseat portion 32. See e.g., co-pending U.S. patent application Ser. No.10/047,077, filed Jan. 31, 2005, which is hereby incorporated byreference herein. In another embodiment, separate control modules may beprovided for the thermal elements 160A, 160B and the fluid modules 92A,92B. In addition, it should be appreciated that the control system 104represents only one exemplary arrangement of a system for controllingthe operation of the climate control system 36. Those of skill in theart will recognize in light of the disclosure herein various otherconfigurations for the control system 104. In addition, one or morecomponents of the control module 110 may be located in variouslocations, such as, within one or both of the fluid modules 92A, 92B orin a separate location.

Various components are described as being “operatively connected” to thecontrol unit. It should be appreciated that this is a broad term thatincludes physical connections (e.g., electrical wires or hard wirecircuits) and non-physical connections (e.g., radio or infraredsignals). It should also be appreciated that “operatively connected”includes direct connections and indirect connections (e.g., throughadditional intermediate device(s)).

The control module 110 optionally may also be configured to receive asignal from a vehicle control device 118 that indicates whether thevehicle's ignition has been turned on. In this manner, the seat controlmodule 110 may be configured to allow operation of the system 36 only ifthe vehicle's engine is running.

In one embodiment, the thermal elements 160A, 160B are activated to heatthe surfaces 48, 50 of the backrest portion 34 and seat portion 32.While the thermal elements 160A, 160B are activated, the fluid modules92A, 92B can provide a fluid flow to the surfaces 48, 50 of the backrestportion 34 and seat portion 32. The fluid may be unconditioned (e.g.,not heated) and in such an embodiment the fluid can enhance the thermalelements 160A, 160B by promoting convection of heat from the thermalelements to the surfaces 48, 50 of the backrest portion 34 and seatportion 32. In another embodiment, while the thermoelectric devices 94B,94B are activated, the fluid modules 92A, 92B provide heated air to thesurfaces 48, 50 of the backrest portion 34 and seat portion 32. In thismanner, the fluid modules 92A, 92B supplement and enhance the heatingeffect provided by the thermal elements 160A, 160B. In yet anotherembodiment, the thermal elements 160A, 160B are used during a first orinitial period of time to heat the surfaces 48, 50 of the backrestportion 34 and seat portion 32 largely through conduction. After thefirst or initial period of time, the fluid modules 92A, 92B can provideconditioned or un-conditioned air to the surfaces 48, 50 of the backrestportion 34 and seat portion 32.

The above described embodiments have several advantages. For example, inparticularly cold conditions, it may take a long period of time to heatnoticeably the seat assembly using heated air provided by the fluidmodules alone. In the above described embodiment, because the thermalelements 160A, 160B are positioned near the surfaces 48, 50 of thebackrest portion 34 and seat portion 32, they can provide immediate heatvia conduction that can be sensed by the occupant of the seat assembly30. The air provided through the distribution system 76A, 76B canenhance (e.g., through convection) or supplement (e.g., by providingconditioned air) the heat provided by the thermal elements 160A, 160B.

Accordingly, in one embodiment the control module 110 can be configuredto use both the thermal elements 160A, 160B and heated air provided bythe fluid modules 92A, 92B during particularly cold conditions (e.g., asdetermined by an appropriately positioned sensor). In addition to or inan alternative embodiment, the control module 110 can be configured touse both the thermal elements 160A, 160B and heated air provided by thefluid modules 92A, 92B when the user selects an elevated (e.g., high ormaximum) setting. In a lower setting (e.g., low and/or medium), only thethermal elements 160A, 160B or the fluid modules 92A, 92B can be used toheat the seat assembly 30.

In addition, some climate control systems are relatively expensive andthus may not be suitable for all applications. In particular, thethermoelectric elements 94A, 94B may be too expensive for someapplications. In such applications, the fluid modules 92A, 92B may beformed without the thermoelectric elements 94A, 94B and may be used tosimply provide air to and/or remove air from the seat surface throughthe distribution system 76A, 76B. In this manner, a low cost climatecontrol system is formed. In such a system, the thermal elements 160A,160B are used to selectively control (e.g., heat) the surfaces of theseat assembly 30. The fluid flow provided by the fluid modules 92A, 92Bcan used to enhance the transfer of heat to the occupant and/or thethermal elements 160A, 160B can be operated alone. When cooling isdesired, the fluid modules 92A, 92B can provide air flow to the seatassembly or withdraw air from the seat surface to provide a coolingeffect.

In a modified embodiment, the fluid module 92A, 92B can include athermoelectric element that is configured to provide only and/orprimarily cooled air to the seat surface through the distribution system76A, 76B. The control module 110 can be configured such that when theuser desires cooling, the fluid module 92A, 92B provides cooled air tothe seat surface. When the user desires heating, the thermal elements160A, 160B can be used to heat selectively the surfaces of the seatassembly 30. During heating, the fluid modules 92A, 92B can providefluid to enhance the transfer of heat to the occupant and/or the thermalelements 160A, 160B can be operated alone. In this embodiment, thecontrol module 110 and fluid modules 92A, 92B can be simplified becausethe thermoelectric element devices do not have to be configured toprovide both cooling and heating functions.

While various embodiments and modes of operation have been describedabove, it is anticipated that the different portions of the seatassembly 30 (e.g., seat and backrest portions) may be controlled inmodified manners and/or controlled to different temperature settings.

FIGS. 5A and 5B illustrate portions of a distribution system 276A, 276Aof a modified embodiment of a climate control system. In FIGS. 5A and5B, like elements to those shown in FIGS. 2A and 2B are designated withthe same reference numbers used in FIGS. 2A and 2B. In addition, onlycertain components of the climate control system will be described indetail below. For those components not described in detail, referencemay be made to the detailed description above.

As with the embodiments described above, the climate control systemgenerally comprises thermal elements 360A, 360B, fluid modules (notshown) and the distribution systems 276A, 276B. In this embodiment, theheating elements 360A, 360B are positioned generally within or proximateto the distribution passages 82A, 82B and/or the inlet passages 78A, 78Bwhich are used to transport air through the seat assembly 30. In thismanner, the heating elements 360A, 360B may be used to heat the airdelivered to the surfaces 48, 50 of the seat assembly 30.

With respect to the illustrated embodiment, the thermal element 160A forthe backrest portion 34 may form at least in part a portion of theinsert 150, which forms the distribution passage 82A. The air flowingthrough the distribution passage is heated by the thermal element 360Aand then delivered to the occupant through the openings 84A. In amodified embodiment, the thermal element 360A may be positioned alongthe inner or outer surface of the insert 150.

With respect to FIG. 5B and the seat portion 32, the thermal elements360B may line and/or form part of the channels 80B in the seat cushion72. As with the backrest 34, the thermal elements 360B heat the airflowing through the passages 82B. In other embodiments, the thermalelements 360B may be positioned within the cushion 72.

Accordingly, with the thermal elements 360A, 360B generally positionedwithin the seat cushion 72 between the seat cover 74 and the backside 56or under side 70 of the seat assembly 30, the thermal elements 360A,360B can heat the air delivered by the fluid module to the seat assembly30. It should be appreciated that in a modified embodiment one or morethermal elements (not shown) can be provided near or adjacent the frontor top surface of the seat. In such an embodiment, the thermal elementscan be provided within the scrim 81A, 81B as described above withreference to FIGS. 2A and 2B.

FIGS. 6A and 6B illustrate portions of a distribution system 1076A,1076B other modified embodiments of a climate control system. In FIGS.6A and 6B, like elements to those shown in FIGS. 2A and 2B aredesignated with the same reference numbers used in FIGS. 2A and 2B. Inaddition, only certain components of the climate control system will bedescribed in detail below. For those components not described in detail,reference may be made to the detailed description above.

As with the embodiments described above, the climate control systemgenerally comprises thermal elements 1160A, 1160B, fluid modules (notshown) and the distribution systems 1076A, 1076B. With reference to FIG.6A, in this embodiment, the distribution system 1076A for the backrestportion 34 includes at least one and preferably a plurality of channels1080A, which are positioned generally on the rear side 56 of the seatcushion 72. At least one and preferably a plurality of through passages1075A extend from the channels 1080A to the front side 54 of the cushion72. The passages 1075A are covered by a cover or scrim 81A, distributionlayer 86A and covering 74, which can be arranged and/or combined asdescribed above with reference to FIGS. 2A and 2B. In the illustratedembodiment, the thermal elements 1160A are positioned within the scrim81A near the openings 84A. An insert 1150 as described above may beprovided within the channels 1080A and/or the passages 1075A. A rearcovering 1002 with an inlet 1004 is provided for defining distributionpassages 82A and connecting the distribution passages 82A to a fluidmodule. In addition, it should be appreciated that in a modifiedembodiment one or more thermal elements (not shown) can be providedwithin or near the channels 1080A or passages 1075A as described belowwith reference to FIG. 6B.

FIG. 6B illustrates the distribution system 1076B for the seat portion32. As with the backrest portion 34 shown in FIG. 6A, the distributionsystem 1076B includes a least one and preferably a plurality of channels1080B, which are positioned generally on the bottom side 60 of the seatcushion 72. At least one and preferably, a plurality of through passages1075B extend through from the channels 1080B to the top side 54 of thecushion 72. The passages 1075B are covered by a cover or scrim 81B,distribution layer 86B and covering 74, which can be arranged and/orcombined as described above with reference to FIGS. 2A and 2B. A bottomcovering 1002 with an inlet 1004 is provided for defining distributionpassages 82B and connecting the distribution passages 82B to a fluidmodule.

In this embodiment, the heating elements 1160B are positioned generallywithin or proximate to the distribution passages 82B as formed by thechannels 1080B and/or through passages 1075B, which are used totransport air through the seat assembly 30. In addition, thedistribution system 1076B of this embodiment does not include an insert.However, as mentioned above, it should be appreciated that certaincomponents and features of the distribution systems 1076A, 1076B for theseat and cushion portions 32, 34 may be exchanged and/or combined. Forexample, the seat portion 32 may include an insert and/or the thermalelements can positioned within the scrim. In addition, it should beappreciated that in a modified embodiment one or more thermal elements(not shown) can be provided near or adjacent the top surface of theseat. In such an embodiment, the thermal elements can be provided withinthe scrim 81B as described above with reference to FIG. 2B.

As mentioned above, in one embodiment, the thermal elements 160A, 160Bcan be used during a first or initial period of time to heat thesurfaces 48, 50 of the backrest portion 34 and seat portion 32 largelythrough conduction. After the first or initial period of time, the fluidmodules 92A, 92B can be used to provide conditioned or un-conditionedair to the surfaces 48, 50 of the backrest portion 34 and seat portion32. FIG. 7 is a graphical illustration of one embodiment of a controlroutine, which can be used in such an embodiment.

As shown in FIG. 7, the user can provide the control unit 110 with a settemperature. For example, the user can choose between high, medium andlow settings, which each correspond to a set temperature. In anotherembodiment, the user can select the temperature (e.g., 100 degrees) on adial or other input device. The controller 110 is configured such thatduring an initial time period d, power is supplied to the thermalelements 160A, 160B while the fluid modules 92A, 92B remain off. In amodified embodiment, during this initial time period d, unconditionedfluid can be provided to the seat by the fluid transfer device 102A,102B to enhance the heating by the thermal elements 160A, 160B. Afterthe initial time period d, the controller 110 can activate the thermalelectric unit 94A, 94B and the fluid transfer device 102A, 102B (if notalready activated). In the illustrated embodiment, there is a transitionperiod in which the power supplied to the fluid modules 92A, 92B isincreased and the power supplied to the thermal elements 160A, 160B isdecreased. During this period, it can be advantageous to keep the totalpower supplied to the thermal elements 160A, 160B and the fluid modules92A, 92B substantially constant. After a certain period of time, thepower supplied to the thermal elements 160A, 160B is terminated whilethe fluid modules 92A, 92B are used to heat the seat assembly 30.

As shown by the arrow a in FIG. 7, the controller 110 can be configuredto start the climate control system 36 when the thermal elements 160A,160B are activated or after an initial time period d. In one embodiment,the time period d is greater than 60 seconds and, in another embodiment,the time period d is greater than 120 seconds. In certain embodiments,the fluid modules 92A, 92B are activated after the thermal elements160A, 160B are turned off. In other embodiments, the fluid modules 92A,92B are activated while the thermal elements 160A, 160B are still beingsupplied power (e.g. as illustrated in FIG. 7).

As mentioned above, because the thermal elements 160A, 160B arepositioned near the surfaces 48, 50 of the backrest portion 34 and seatportion 32; they can provide immediate heat via conduction that can besensed by the occupant of the seat assembly 30. This can be particularlyadvantageous in cold conditions where it may take a long period of timeto heat noticeably the seat assembly using heated air provided by thefluid modules alone. After a period of time the fluid modules 92A, 92Bprovide a sufficient amount of heated air to the user that the powersupplied to the thermal elements 160A, 160B can be turned off orsignificantly reduced. The transition from using the thermal elements160A, 160B to using the fluid modules 92A, 92B to provide heating ispreferably configured such that the user does not notice the transition.

To assist in the description of the disclosed embodiments, words such asupward, upper, downward, lower, vertical, horizontal, upstream, anddownstream have been used above to describe the accompanying figures. Itwill be appreciated, however, that the illustrated embodiments can belocated and oriented in a variety of desired positions.

In the above description, various components are described as beingassociated with the “back” or “seat” cushion. In modified embodiments,it should be appreciated that the subcomponents of the back and seatcushions may be reversed and/or made to the same. In still otherembodiments, the various components of the illustrated embodiments maybe combined and/or may be applied to different zones of a seat, such as,for example, a top and bottom portion of a backrest portion. In otherembodiments, the features of the back and seat cushions may be appliedto different zones of an occupant area that are to be thermallyconditioned, such as, for example, back and rear seat assemblies or leftand right seat assemblies.

Although the foregoing description of the preferred embodiments hasshown, described, and pointed out certain novel features, it will beunderstood that various omissions, substitutions, and changes in theform of the detail of the apparatus as illustrated, as well as the usesthereof, may be made by those skilled in the art without departing fromthe spirit of this disclosure. Consequently, the scope of the presentinvention should not be limited by the foregoing discussion, which isintended to illustrate rather than limit the scope of the invention.

1. A method for thermally conditioning a seat assembly, the methodcomprising: providing a seat cushion that defines a support surface anda seat covering that covers the support surface of the seat cushion;wherein the seat assembly comprises at least one resistive heatingelement positioned within the seat assembly beneath the seat covering,said at least one resistive heating element configured to conductivelyheat a space adjacent the seat assembly; wherein the seat assemblycomprises at least one fluid module positioned generally away from theseat covering, said at least one fluid module configured to convectivelyheat a space adjacent the seat assembly, wherein said at least one fluidmodule comprises a blower and a thermoelectric device; receivinginstructions from an occupant regarding a desired operational settingfor the seat assembly; sensing a temperature associated with an actualthermal condition at or near the space adjacent the seat assembly usingat least one temperature sensor; providing information regarding thedesired operational setting and temperature to a control module, saidcontrol module being configured to operate the at least one heatingelement and the at least one fluid module; wherein the control module isadapted to selectively regulate the at least one heating element and theat least one fluid module to thermally condition the space adjacent theseat assembly according to a target control scheme; activating ordeactivating at least one of the at least one heating element, theblower and the thermoelectric device based on the target control scheme;during a first conditioning mode, activating the at least one heatingelement to conductively heat the space adjacent the seat assembly;during a second conditioning mode, activating at least one of the blowerand the thermoelectric device to convectively heat the space adjacentthe seat assembly; and after a period of time, deactivating the at leastone heating element; wherein the first conditioning mode generallyprecedes or is used concurrently with the second conditioning mode;wherein a target desired temperature at the space adjacent the seatassembly is attained more quickly by activating the at least one heatingelement than by only directing heated air from the at least one fluidmodule; and wherein deactivating the at least one heating element helpsreduce total power consumption of the seat assembly while maintaining adesired level of comfort for the occupant.
 2. A method as in claim 1,wherein the at least one heating element comprises a resistive heater.3. A method as in claim 1, further comprising generating heat within aspace generally beneath the seat covering of the seat assembly.
 4. Amethod as in claim 1, further comprising generating heat within a spacegenerally beneath the seat covering of the seat assembly and generallyabove the seat cushion of the seat assembly.
 5. A method as in claim 1,wherein the step of activating the at least one fluid module begins atleast 60 seconds after the at least one heating element has beenactivated.
 6. A method as in claim 1, wherein the step of activating theat least one fluid module begins at least 120 seconds after the at leastone heating element has been activated.
 7. A method as in claim 1,wherein the step of activating the at least one fluid module beginsafter the at least one heating element has been deactivated.
 8. A methodas in claim 1, wherein the steps of activating the at least one heatingelement and activating the at least one fluid module occur substantiallysimultaneously.
 9. A method as in claim 1, wherein the at least oneheating element and the at least one fluid module are both activatedduring a period of time, wherein during said period of time the totalcurrent supplied to a climate control system of the seat assemblyremains substantially constant.
 10. A method for selectively heating aspace adjacent a seat assembly that includes a seat cushion that definesa support surface and a seat covering that covers the support surface ofthe seat cushion, the method comprising: receiving instructions from anoccupant regarding a desired operational setting for the seat assembly;sensing a temperature associated with a level of actual thermalconditioning occurring at the seat assembly using at least onetemperature sensor; providing the desired operational setting and asensed temperature to a control module; wherein the control module isadapted to selectively regulate a heating element and a fluid module tothermally condition a space adjacent the seat assembly according to acontrol scheme, said fluid module comprising a fluid transfer device anda thermoelectric device; wherein said control scheme comprises a firstthermal conditioning mode and at least a second thermal conditioningmode; during the first thermal conditioning mode, activating the heatingelement to conductively heat a space adjacent the seat assembly; andduring the second thermal conditioning mode, transferring air using thefluid module to a space adjacent the seat assembly through adistribution system formed in the seat cushion to selectively heat thespace adjacent the seat assembly; and wherein the first thermalconditioning mode and the second thermal conditioning mode areconfigured to overlap for at least a portion of time so that the heatingelement and the fluid module are operated concurrently to provide anenhanced heating effect to a seated occupant.
 11. The method of claim10, wherein the desired operational setting for the seat assemblycomprises a general temperature setting.
 12. The method of claim 10,wherein the desired operational setting for the seat assembly comprisesa specific temperature or temperature range.
 13. The method of claim 10,wherein the seat assembly comprises a seat back portion and a seatbottom portion, wherein the desired operational setting for the seatback portion is different that the desired operational setting for theseat bottom portion.
 14. The method of claim 10, wherein the heatingelement comprises a resistive heater.
 15. The method of claim 10,wherein the second thermal conditioning mode begins at least 60 secondsafter an initiation of the first thermal conditioning mode.
 16. Themethod of claim 10, wherein the second thermal conditioning mode beginsat least 120 seconds after an initiation of the first thermalconditioning mode.
 17. The method of claim 10, wherein the secondthermal conditioning mode begins generally simultaneously with the firstthermal conditioning mode.